Webasto Thermo Top E Installation Instructions Manual

Thermo Top E
Webasto
Brand
Webasto
Model
Thermo Top E
Type
Installation Instructions Manual

This manual is also suitable for

WARNING!
Hazard warning:
Incorrect installation or repair of Webasto heating systems may cause a fire or result
in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can
be caused as a result.
Specialist company training, technical documentation, specialized tools and
equipment are required to install and repair Webasto heating and cooling systems.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not
successfully completed the company training and thereby acquired the required
technical skills or if you do not have access to the required technical documentation,
tools and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all
warning instructions.
Webasto does not accept any liability for defects and damage that are attributable to
an installation by untrained staff.
Feel the drive
Suzuki Grand Vitara
Diesel
From model year 2006
Valid for vehicle frame no.: JSAJTD44...
For left-hand drive vehicles only
Ident. no. 1310833A €10 fee © Webasto AG
Water Heater Unit
Thermo Top E Auxiliary
Heating
Thermo Top C Auxiliary
Heating
Thermo Top P Auxiliary
Heating
Installation Instructions
e1
00 0003
e1
00 0002
e1
00 0104
22
Suzuki Grand Vitara
Validity
Vehicle and engine types, equipment variants as well as national specifications, which are not listed in
these installation instructions, have not been tested. Installation according to these installation
instructions may, however, be possible.
The installation location of a time switch and summer / winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No. / ABE
Suzuki Grand Vitara JT e4 * 2001 / 116 * 0091 * ...
Engine type Engine Power in kW Engine capacity in cm³
F9Q Diesel 95 1870
Validity 2
Heater Unit / Scope of Delivery 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on the Document 4
Preliminary Work 5
Heater Unit Installation Location 5
Preparing the Electronics 6
Electrical Connections 7
Automatic air conditioning blower control 8
Time switch 10
Summer / winter switch option 10
Remote Start Option 10
Thermo Call Option 11
Preparing the Installation Location 12
Preparing the Heater Unit 13
Installing the Heater Unit 14
Water Connection 15
Fuel Connection 18
Exhaust System 20
Final Work 21
Operating instructions for the end customer 22
Table of Contents
33
Suzuki Grand Vitara
Heater Unit / Scope of Delivery
Also required:
Optional control element selection:
Recommended heater unit for the relevant vehicle class:
Select the heater unit based on the size of the vehicle passenger compartment and the customer's
comfort requirements.
Foreword
These installation instructions apply to vehicles Suzuki Grand Vitara with Diesel engines.
– Re. validity, see page 2 – from model year 2006 and later, assuming technical modifications to the
vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and
equipment, modifications may be necessary during installation with respect to these installation
instructions.
However, the stipulations in the "installation instructions" and "operating and maintenance instructions"
for the Thermo Top C/P/E are to be observed in any event.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless
specified otherwise, fasten hoses, lines and cable harnesses to original vehicle lines and cable
harnesses using cable clips.
Sharp edges should be fitted with edge protectors (split open plastic hose).
Spray unfinished body areas, such as for example bore holes, with anti-corrosion wax (Tectyl 100K,
Order No. 111329)!
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vise-grip wrench
- Riveting nut tool
- Angle drill
Amount Description Order No.:
1 Suzuki-specific heater scope of delivery See Suzuki price list
Amount Description Order No.:
1 Installation kit for Suzuki Grand Vitara Diesel from
year 06 1 310 827A
Description Order No.:
Control elements See Suzuki price list
Vehicle Heater unit
Compact car Thermo Top E
Mid-class, station wagon Thermo Top C
Luxury, van, off-roader Thermo Top P
44
Special features are highlighted using the following symbols:
Mechanics
Electrics
Water connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Suzuki Grand Vitara
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehicle-
specific documents.
Reference to a special technical feature.
i
Explanatory Notes on the Document
To provide you with a quick overview of the individual working steps, you will find an identification mark
on the outside top right corner of the page in question.
5
Suzuki Grand Vitara
Heater Unit Installation Location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Disconnect the battery.
- Let off pressure in the cooling system.
- Copy the factory number from the original type label to the duplicate type label.
- Remove years that do not apply from the duplicate label.
- Attach the duplicate label (type label) in the appropriate place.
- Completely remove the battery.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the underride protection
- Remove air conditioning control according to manufacturer's instructions.
- Remove the lower cover to the passenger-side footwell
- Remove the lower cover to the driver-side footwell (for Thermo Call only)
- Remove panel on A-pillar on passenger side (only for Telestart and / or Thermo Call)
6
Suzuki Grand Vitara
Preparing the Electronics
Cutting
wire into
sections
Connect according to the circuit diagram.
Pull the wire section 2 into the enclosed
insulation hose and, later, in the passenger
compartment.
Preparing
fuse F4
sw 1,0mm²
2900
1 2
100
F4 10A
sw
1sw
2
86
85 30
87a87
K3
rt/
ws
gn/ws rt
swbr
7
Suzuki Grand Vitara
Electrical Connections
Positive and ground connection
1Ground wire to the original vehicle chassis
ground point
2Positive wire to battery positive terminal
distributor
Cable harness feed-through
1Protective rubber sleeve
2Blower controller cable harness, time switch
and sw (black) additional line in the insulation
hose
Cable
harness
installation
diagram
Fuse holder, K3 relay
2K3 relay
1Bend up the shackle, M5x12 bolt, washer [2x],
flanged nut on existing bore hole
4Fuse holder retaining plate, M5x12 bolt,
washer [2x], flanged nut on existing bore hole
3Fuse holder
Installing the cable harnesses
1Run the heater unit cable harness to the
metering pump installation location (see figure
16)
1
2
2
3
1
rt
sw
1mm²
sw
br
bl
i
4
4
21
35
1 1
8
Suzuki Grand Vitara
Automatic air conditioning blower
control
Connection to 2-pin connector 1 from the
blower motor.
Connect with enclosed butt connectors
according to the circuit diagram.
2Blue/white (bl/ws) wire from blower relay
4Red (rt) wire from K3/87a
5Blue/white (bl/ws) wire to blower motor
plug
3Black (sw) wire from K3/30
Connect-
ing the
blower
motor
Connection to 32-pin connector 1 G52 grey.
Connect with enclosed butt connector
according to the circuit diagram.
2Black (sw) wire from fuse F4
4Original vehicle wire violet/red (vi/rt) from
connector G52 pin 1
3Original vehicle wire violet/red (vi/rt) from
fuse F40
Connect-
ing the air
condition-
ing control
1 Pin 1 from connector G52 contact side
Air
condition-
ing control
connector
6
21
5 4
3
7
1 2
3
4
3 41 2 7 85 6 11 12910 15 1613 14
19 2017 18 23 2421 22 27 2825 26 31 3229 30
1
9
Suzuki Grand Vitara
Automatic
air
condition-
ing circuit
diagram
Webasto components Suzuki components Colors and symbols
Legend
HG Heater unit TT-C/E GM Blower motor rt red
X1 6-pin heater unit
connector GR Blower relay ws white
F3 Fuse KB Air conditioning control sw black
K3 Blower relay 25A G52 32-pin air conditioning
control connector br brown
F4 Additional fuse 10A F19 Fuse, 40A gn green
F40 Fuse, 10A bl blue
vi purple
Insulate and tie back
wire ends
XSplitting point
Cable colors may vary.
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Suzuki Grand Vitara
rt
F3
4
HG
X1
F4
sw
sw
K3
87a8786
85 30 bl/ws
M
+
-
GM
F19 F40
KB
1G52
rt/sw
GR
vi/rt
vi/rt
!
1 2
i
10
Suzuki Grand Vitara
Time switch
1Time switch
Assem-
bling the
time switch
Summer / winter switch option
1Summer / winter switch, bore hole Ø12 mm
Assem-
bling the
summer /
winter
switch
Remote Start Option
2Fan housing
1Receiver, Velcro tape (self adhesive)
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
1
8
i
1
9
i
1
2
10
i
11
1
11
Suzuki Grand Vitara
Temperature gauge (only for HTM 100)
1Temperature gauge
2Velcro tape (self adhesive)
3Air duct
Assem-
bling the
tempera-
ture gauge
Thermo Call Option
1Receiver, Velcro tape (self adhesive 2x)
Assemblin
g the
receiver
1Antenna
Assem-
bling the
antenna
1Tip switch
Assem-
bling the
tip switch
12
23
1
113
i
14
1
1
15
12
Suzuki Grand Vitara
Preparing the Installation Location
Run the heater unit cable harness 2 to
position 1, make loop, run back to the heater
unit installation location. Run the metering
pump cable 3 to the metering pump
installation location. Installing
the cable
harness
1Heater Unit Installation Location
2Heater unit cable harness
Installing
the cable
harness
Transfer hole image according to figure Drill
Ø 7mm holes at position 1 and 3. First drill Ø
7mm holes through the first two levels at
position 3 and later drill the lower level to Ø
16mm.
Drilling
holes
Finish the enclosed spacer washers
according to the figure.
18mm spacer
25mm spacer
Finishing
the spacer
washers
16
1
2
3
17
1
2
18
1
3
2
195mm
190mm
25mm
81mm
8mm
2
1
2mm 2mm
13
Suzuki Grand Vitara
Preparing the Heater Unit
Enclosed hose 30° Ø 20mm
Enclosed molded hose 180° Ø 20mm
b = 975mm
c = 780mm
Dispose of sections X
Cut off hose C just after the bend
Cutting
water hose
into
sections
Slide the braided protective hose onto hose B
and hose C and cut into sections.
Divide the shrink-fit hose into 4 equal ends,
slide on and shrink.
1Shrink-fit hose [4x]
Preparing
the water
hoses
Fasten the hose C with 90° bend onto the
heater unit water outlet, fasten hose B with
90° bend to the circulation pump.
1Ø 27mm hose clamps [2x]
2Heater unit
4Mecanyl fuel line
3Hose section, Ø 10 mm hose clamps [2x] Preassem-
bling the
heater unit
Note the installation position of the air intake
silencer, see the Installation Instructions.
Punch out the perforation in the header unit
cover, insert the retaining clip 2.
1Combustion air intake pipe
3Ejot stay bolts [3x]
4Ø 27 mm hose clamp
510mm spacer, bolt protector
6Combustion air intake silencer
Pre-
assem-
bling the
intake
silencer
b c
B
X
C
X
X
DA
B
1 1
C
1 1
B
19
2
1
C
13
4
20
3
5
6
3
3
4
1 2
i
14
Suzuki Grand Vitara
Installing the Heater Unit
Before assembling the heater unit, lower the
crossarm 3 and replace the original vehicle
bolt at position 4 with an M6x30 bolt.
1Spacer with recess 8 mm
2Spacer with recess 5mm, body washer
5Ø 48 clip with rubber removed, 5 mm
spacer, MG flanged nut
Loosely
assem-
bling the
heater unit
1Wind deflector
2M6 flanged nuts [2x]
Assem-
bling the
wind
deflector
1Flanged nut M6
Tighten the crossarm 2 again.
Assem-
bling the
heater unit
21
1
3
2
4
5
22
2
1
23
1
2
15
Suzuki Grand Vitara
Water Connection
WARNING!
Tighten all hose clamps with 2.0 + 0.5 Nm.
Any coolant running off should be collected using an appropriate container.
Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable clips.
Position hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Water
installation
diagram
All undesignated clamps are Ø 20-27 mm hose clamps. Position X = original vehicle spring band
clamps. 1 Connecting pipes = Ø 20x20 with spring band clamps Ø 27.
Motor
A
C
D
B
X
X
Wärme-
tauscher 1
1
Heat
exchanger
16
Suzuki Grand Vitara
Remove the original vehicle hose 1 from the
motor outlet to the heat exchanger inlet and
dispose. The spring band clamps will be used
again.
Splitting
point
Ensure sufficient distance from adjacent
components.
1Bore hole Ø 9.1mm, M6 rivet nut, M6x20
bolt, spring washer
2Rubberized tube clamp Ø 48mm
3Edge protection [2x] Placement
on the
underbody
1Original vehicle spring band clamp.
Connect-
ing to the
heat
exchanger
inlet
1Original vehicle spring band clamp.
Connect-
ing to the
engine
outlet
24
1
25
C
1 2
B
3
3
26
C
D
1
27
B
1
A
17
Suzuki Grand Vitara
Check the entire length of the water hoses
and correct if necessary. Fasten the water
hose B to the cable harness with cable ties 1.
Installing
in the
engine
compart-
ment
28
B
A
1
18
Suzuki Grand Vitara
Fuel Connection
CAUTION!
Open the vehicle's tank-cap lock, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with an appropriate container.
Install fuel line and metering pump cable harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable clips.
Fit the fuel line and cable harness with edge protectors around sharp edges.
WARNING!
The fuel line and cable harness to the metering pump should be installed based on the cable harness
installation diagram.
1Fuel line from the heater unit
2Metering pump cable harness
Installing
lines
1M8x20 washer, washer, spring washer on
existing threaded hole
2Angle bracket
3Metering pump
4Rubberized tube clamp
5Silent block, flanged nut [2x] Assem-
bling the
metering
pump
Fuel line from the heater unit on the pressure
side of the metering pump [side with
connector].
2Mecanyl fuel line
3Hose section, Ø 10 mm hose clamps [2x]
1Metering pump cable harness, wire seals,
flat connector [2x], connector housing Connect-
ing to
metering
pump
29
2
1
30
1 2
4
3
5
31
32
1
19
Suzuki Grand Vitara
Separate the leading fuel line 1 according to
the figure and insert the fuel extractor.
2Separation location, fuel extractor, Ø 10
mm hose clamps [2x].
Fuel take-
off
1Hose section, Ø 10 mm hose clamps [2x].
2180° molded hose, hose clamps [2x]
3Cable clip
4Mecanyl fuel line
Connect-
ing to
metering
pump
32
1
1
2
33
1 2
34
20
Suzuki Grand Vitara
Exhaust System
1Exhaust pipe
a = 560mm
2Exhaust end section
b = 90mm
Dispose of section X
Preparing
the
exhaust
pipe
1Silencer
220mm spacer
3M6x40 bolt, body washer, M6 flanged nut
on existing hole
Assem-
bling the
silencer
Slide the exhaust insulation 3 on the exhaust
line.
1Exhaust pipe
2Hose clamp [2x]
Assem-
bling the
exhaust
pipe
2Exhaust pipe
3Exhaust end section
1Hose clamp [2x]
Assem-
bling the
exhaust
line and
end piece
a b
1 2
X
34
2
1
3
1
2
35
3
1
2
36
3
1
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Webasto Thermo Top E Installation Instructions Manual

Thermo Top E
Webasto
Brand
Webasto
Model
Thermo Top E
Type
Installation Instructions Manual
This manual is also suitable for
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